🏷️ Basic Information

Make:

Gilera

Model:

Fuoco 500 i.e.

Year:

2007

Engine Code:

M318

Chassis Code:

ZAPM318

👋 Introduction

Target Audience:

Gilera Fuoco 500 i.e. owners, independent repair shops, and motorcycle enthusiasts seeking in-depth service information.

Value Proposition:

Provides professional-level repair and maintenance information, enabling users to perform complex tasks, save on labor costs, and maintain their vehicle's condition effectively. Offers a significant advantage over generic online resources.

Ease Of Use:

Downloadable PDF format allows for viewing on various devices, selective printing of pages as needed, and re-printing of soiled pages, offering flexibility and convenience.

Instant Access:

Immediate download after purchase eliminates shipping delays and costs, providing instant access to critical service information.

Completeness:

Covers all aspects of the vehicle's maintenance and repair, aiming to be the 'ONLY' workshop service manual required.

📋 Manual Details

Overall Coverage:

Complete vehicle

Specific Systems Covered:

Engine, Gearbox & Clutch, Cooling System, Fuel System, Braking System, Suspension, Electrical System, Body & Fixtures, Exhaust System, Wheels & Tyres, Maintenance, Technical Information & Specifications

Estimated Page Count:

300-500 (estimated for comprehensive coverage)

Type:

Workshop Service & Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Detailed breakdown, disassembly, assembly, inspection, and repair of all engine components including cylinder head, valves, pistons, crankshaft, camshaft, timing system, lubrication, and cooling.

Transmission:

Servicing and repair of the automatic transmission (CVT), including variator system, clutch, and final drive unit. Gearbox overhaul procedures.

Braking System:

Inspection, maintenance, and repair of front and rear disc brakes, brake lines, master cylinders, calipers, and ABS system components (if applicable).

Suspension:

Front suspension (double wishbone) and rear suspension system overhaul, including shock absorbers, springs, linkages, and alignment procedures.

Electrical System:

Comprehensive electrical schematics, wiring diagrams, troubleshooting guides for ignition, lighting, starting, charging, fuel injection, instrument panel, and electronic control units (ECUs).

Fuel System:

Maintenance and repair of the electronic fuel injection (EFI) system, including fuel pump, injectors, throttle body, fuel filter, and pressure regulator.

Cooling System:

Radiator, coolant hoses, water pump, thermostat, and fan operation and maintenance. Bleeding procedures.

Body And Fixtures:

Body panel removal and installation, seat adjustment, lighting fixtures, fairings, and interior trim.

Exhaust System:

Inspection, maintenance, and replacement of exhaust components, including mufflers and catalytic converters.

Wheels And Tyres:

Tyre inspection, replacement, balancing, and wheel specifications. Rim care and maintenance.

Maintenance Procedures:

Regular servicing, oil changes, filter replacements, spark plug replacement, brake fluid changes, coolant checks, battery maintenance, and lubrication points.

Repair Procedures:

Step-by-step instructions for component repair and replacement for all major vehicle systems, including engine rebuilds, transmission overhauls, and electrical diagnostics.

Troubleshooting:

Diagnostic procedures for common and uncommon faults, including symptom-based troubleshooting guides and wiring diagram analysis.

Technical Adjustments:

Fuel system adjustments, idle speed settings, suspension alignment, and brake adjustments.

Depth:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and torque specifications.

📊 Manual Specifications

Format:

PDF

Searchability:

Likely searchable text content for easy navigation.

Quality:

High resolution for clear viewing and printing of exploded diagrams and text.

Binding:

N/A (Digital Download)

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Four-stroke, single-cylinder, liquid-cooled, SOHC, 4 valves

Displacement:

492.7 cc

Bore X Stroke:

94 mm x 71 mm

Compression Ratio:

10.4:1

Claimed Horsepower:

43.5 HP (32 kW) @ 7500 rpm

Claimed Torque:

48 Nm (35 lb-ft) @ 5000 rpm

Fuel Delivery:

Electronic Fuel Injection (EFI) with Keihin electronic control

Throttle Body Diameter:

50 mm

Fuel Type:

Unleaded gasoline

Ignition System:

Electronic ignition with variable advance

Lubrication System:

Wet sump with trochoidal oil pump

Cooling Type:

Liquid-cooled

Cooling Fan Activation:

Temperature-controlled electric fan

🔧 Transmission

Type:

Automatic Continuously Variable Transmission (CVT)

Clutch:

Automatic centrifugal dry clutch

Final Drive:

Belt drive and chain drive to rear wheel

Variator System:

Automatic variator unit with roller weights for gear ratio adjustment.

📐 Dimensions

Length:

2230 mm

Width:

800 mm

Height:

1505 mm (to handlebars)

Wheelbase:

1590 mm

Dry Weight:

240 kg

Gross Vehicle Weight Rating:

Approx. 420 kg (estimated)

Weight Distribution:

30/70 front/rear (rider dependent)

Fuel Tank Capacity:

12 liters

Oil Capacity:

1.4 liters (approx., including filter)

🛡️ Safety Features

Crash Test Results:

N/A (Motorcycle)

Braking System:

Dual 280 mm front discs with 4-piston calipers, 240 mm rear disc with 2-piston caliper. ABS available on some models/regions.

Lighting:

Halogen headlight, LED taillight, turn signals.

Chassis Design:

Robust steel trellis frame for rigidity and stability.

Suspension Stability:

Wide track and dual front wheels contribute to stability.

💡 Technology Features

Instrument Panel:

Digital dashboard with speedometer, tachometer, odometer, trip meter, fuel level indicator, coolant temperature gauge, and warning lights.

ABS:

Anti-lock Braking System (ABS) may be an optional feature depending on the market and specific model variant.

Diagnostic Ports:

On-board diagnostic (OBD) port for engine management system analysis.

Headlight Type:

Halogen

🔧 Maintenance

First Service:

1000 km or 6 months (whichever comes first)

Subsequent Service:

Every 6000 km or 12 months

Engine Oil Change:

Every 6000 km or 12 months

Air Filter Check:

Every 6000 km or 12 months, replace as needed

Spark Plug Replacement:

Every 12000 km or 24 months

Engine Oil Type:

SAE 5W-40, API SG/SH/SJ/SL/SM, ACEA A3/B3, JASO MA/MA2 certified

Coolant Type:

Ethylene glycol based antifreeze with corrosion inhibitors (e.g., Paraflu UP or equivalent)

Brake Fluid Type:

DOT 4

Transmission Oil Type:

Refer to manual for specific final drive oil (e.g., SAE 80W-90)

Common Problems:

Occasional issues can include CVT belt wear, water pump seal leaks, and starter motor solenoid problems. Electrical connectors can be susceptible to corrosion in damp environments.

Preventative Measures:

Regularly clean the CVT intake and exhaust, check for coolant leaks, and ensure all electrical connections are clean and sealed.

📚 Vehicle History

Gilera Legacy:

Gilera is an Italian manufacturer with a long history in motorcycle racing and production, known for performance-oriented and innovative designs.

Fuoco Development:

The Gilera Fuoco 500 is closely related to the Piaggio MP3, sharing much of its platform and engine, but with a distinct design and market focus as a more rugged, off-road-inspired scooter-like vehicle.

Manufacturing Location:

Italy

Production Period:

Introduced in 2007

🏆 Awards & Recognition

Industry Acknowledgment:

While specific awards for the 2007 Gilera Fuoco 500 are not widely documented, it was recognized for its innovative three-wheel design (shared with the Piaggio MP3) and powerful engine in the scooter/maxi-scooter segment.